Bulging of case on
ONE SIDE could be caused by tilted bullets, out of round bullets, inconsistent case wall thickness, etc.
Since the OP is experiencing one sided bulging on some of the finished rounds, I would rule out issues with sizing die or the expander and look at seating of the bullet, bullets being out of round and case wall variation:
1. To check for tilted bullets, roll the finished rounds with one sided bulge on the bench and if the bullet tips wobble, the bullets are getting tilted during seating. If the bullet tips don't wobble, then something else is causing the bulge on one side of the case (perhaps the bullets are out of round).
2. To check for out of round bullets, measure the bullet diameter at several places around the bullet (you can also pull the bullets with one sided bulge and check). If the rounds with one sided bulge do not wobble and the bullets are not out of round, then as Walkalong posted, I would suspect irregular case wall thickness as the reason for one sided bulging of case wall.
3. To check for irregular case wall thickness, measure the case wall thickness at multiple points around the case mouth of the one sided bulged case.
Lee seating die comes with rounded bullet seating stem and even with 115 gr Winchester FMJ sized .355" with rounded nose, I got tilting of the bullet to produce pronounced bulge on one side of the case when I was rushing to seat the bullet (see comparison pictures below). After noticing the bulge, I confirmed the tilted bullets by rolling the rounds on the bench and they wobbled. I checked the seating stem and it was clean without any gunk build up. When I slowed down and more carefully seated the bullet, the bulging subsided and was more uniform around the case. When I rolled the finished rounds on the bench, the bullet tips wobbled less.
Rounds with tilted bullets showing pronounced bulge on one side of the case that wobbled when rolled
Rounds with less bulge that was more even around the case and wobbled less when rolled